Metal Cutting

Material removal through cutting, turning, milling, drilling, grinding, tapping and more using machinery such as laser cutting systems, plasma cutting systems, oxyfuel cutting systems, milling machines, drill presses, lathes, horizontal machining centers, vertical machining centers, turning centers, multitasking machines, electrical discharge machines and other equipment assisted by Computer Aided Design (CAD), Computer Aided Manufacturing (CAM), Computer Numerical Control (CNC), automation and robotics.

A Chip Off the Old Block

Dart masters the "peaks and valleys" of custom engine block production with an advanced American-made Sunnen SV-20 flexible honing system that uses programmable control to replicate “best” engine parameters and produce expert results with minimal operator expertise.
Experts
Automation/Robotics

Intelligent Factories: The Fourth Industrial Revolution

The biggest challenge for intelligent metalworking shops is implementing the correct individualized manufacturing systems on the software side that can fit their unique needs and provide competitive advantages.
A new era of highly efficient, flexible and customizable mass production requires software and analytical systems that turn the deluge of data produced by intelligent factories into useful and valuable information.
CAD/CAM Software

Mission Accomplished

Robotic metal polishing; Mico Industries.
Thanks to SolidCAM iMachining, cycle times are down 50 percent, tool life is up 40 percent, and Mico Industries is creating dies, weld fixtures and check fixtures without compromise.
Drilling Machines

Making Natural Gas Clean with a “Hole” Lot of Pressure

A pressure vessel in the mid-fabrication stages. The pressure vessels Mueller Environmental manufacturers measure anywhere from 4 ft to 8 ft in diameter and are made from ½ in to 3 1/2 in thick 5617 rolled steel plate. The diameter and material thickness depends upon the pressure the vessel must withstand. Sometimes pressures can reach as high as 3,000 psi.
Using a modified HMD915 magnetic drill and Industrial Series of Rotabroach Cutters from Hougen enabled Mueller Environmental to cost-effectively develop a patented new system for cleaning natural gas.
Gear Cutting Machines

Gear Production: Higher Speed, Closer Precision

The accuracy of the Fast Gear Alignment function eliminates the need to acquire acoustic signatures during dressing or grinding. Aligning a grinding wheel with a 180 mm diameter gear with 71 helical teeth takes just 0.5 of a second – without any need to acquire acoustic signatures or make manual adjustments. 
Automated threaded wheel grinding on gear production machines has now been boosted by an order of magnitude with increased machining accuracy to DIN class 3.
Grinding Machines

New Honing Process Produces High-Precision in Manufacturing

Single Stroke Honing from Sunnen is a single-pass process that sizes and finishes a bore with a series of progressively larger superabrasive tools adjusted to a pre-set diameter. Single Stroke Honing tools rotate while passing through the bore one time and then withdrawing. The machine's servo-controlled stroking system provides flexibility with adjustable speed and various feed profiles, such as pecking, short stroke, dwell, etc. Column feed and spindle speed can be varied throughout a cycle using the machine control. 
Developed in Europe by Sunnen Products Company, the Single Stroke Honing® process for cast-iron hydraulic valve bodies produces less than 2 µm cylindricity in bores, achieving almost 200 percent more precision than previously possible.
Honing Machines

Smart Honing Lifts Business for Aerospace Hydraulic Pumps

The work envelope of the honing machine shows air-bearing index table in foreground, robot to left, honing spindle and tool upper center, and air gage right. 
This second generation machining business is using a new technology that makes a 60 millionths tolerance look generous. No kidding.
Horizontal Machining Centers

Advanced Machining Allows Subsea Valves To Handle the Pressure

Operating a DMG / Mori Seiki NL2500 at BEL Valves.
BEL Valves uses a variety of DMG / MORI SEIKI machine tools to meet its paramount need for reliability during production. 
Laser Cutting

Micromachining: No More Constraints

Prototyping time for new nozzle designs is reduced from weeks in the machine shop to 24 hours with the R-Drill, dramatically accelerating design optimization and time to market. The R-Drill reduces drilling time by approximately 30 percent while increasing yield to nearly 100 percent, with no need for expensive post-processing to correct HAZ damage.
The latest femtosecond laser technology from Raydiance can reduce cost per part by 20 percent to 50 percent and reduce product design, prototyping and development from months to as little as 24 hours.
Lathes

Hard Thread Turning Shortens The Process Chain

Figure 1. High rigidity allows higher process forces: Hembrug turning machines are especially suitable for high-precision hard turning.
High precision hard turning techniques are enjoying ever greater popularity in the metal processing industry. By shortening cycle times and increasing flexibility, high precision hard turning has advantages over grinding in particular when it comes to processing complicated parts such as spindle nuts or threaded spindles in the hard state.
Machine Controls

Custom CNC Helps Break New Ground

Innovative flying optics can position the XO machine’s laser beam anywhere within a 1.5 x 3 metre working area, to an accuracy of ±0.01 mm.
NUM develops special hardware and software for the XO laser cutter of Favor Laser, marking the company's entry into the high performance end of the market.
Milling Machines

Boring Mill Fuels Energy Sector Expansion for Machine Shop

The dual-pallet, rotary table Giddings & Lewis MC 1600 horizontal boring mill (HBM) from Fives is designed for multi-axis contour milling, precision boring, drilling and tapping. It will produce a variety of large parts for Milwaukee Machine Works, including wind turbine gearbox housings and fluid end manifolds for the oil/gas industry.
Milwaukee Machine Works expands its energy sector business into wind turbine gearbox housings, fluid end manifolds for the oil/gas industry, and other oversized components up to 10 ft long and weighing up to 7,000 lb with a new large capacity dual-pallet Giddings & Lewis MC 1600 from Fives.
Multitasking Machines

A New Look at Pipeline Intervention

Machined pipes in the Badentoy plant. In the pipeline section, the tubes are 2.375 in to 14 in diameter and 40 ft long. They can also be slightly bent, which puts tremendous force on the machine tool bearings and toolpost.
The DMG Mori machine tools used by Hunting Energy Services play a crucial role in manufacturing well intervention equipment and threaded tubulars for the oil and gas industry.
Ram EDM Machines

A Hole New Game: Precision EDM Holemaking Goes Smaller, Deeper and Faster

Technically advanced EDM drill systems merge hole popper technology with die-sinker digital generator technology for more precise spark control that essentially puts the holemaking accuracy in the technological hands of the machine tool.
While hole-popper systems are quite capable of generating very small accurate holes with good surface quality, advanced EDM drilling systems dramatically increase a shop’s capability to consistently produce tiny holes that are even more accurate and with higher quality.
Software

How to Simplify Complex Geometry Tool Repair

By enabling the entry point of the grinding wheel to follow the corner radius of the cutting edge, the software now facilitates the grinding of a defined rake angle on complex body forms and on cutting edges which pass from the body of the tool to its tip – a task that was previously extremely difficult to achieve.
A new release of NUMROTO tool grinding software meets the growing challenges of grinding and servicing new generations of complex geometry drills and end mills.
Vertical Machining Centers

Corporate Profile: Makino

(Click on image to enlarge it)
An overview of the company and its organization, products, services and capabilities.
Turning Centers

He Who Brakes, Wins

Automated production at Precima includes batch sizes of 2,000 brake housings per week.
To be able to produce 40,000 brakes a month and maintain consistent quality, Precima invested in four advanced vertical pick-up turning machine tools from EMAG to produce housings for brakes used primarily in wind turbines.
Wire EDM Machines

Wire Changing EDM Proves Big in Micro Tooling Production

Mike (right) and Eric Blackwell of Scenic Tool and Stamping rely on a CUT 2000 wire EDM from GF AgieCharmilles that uses new third-generation twin-head automatic wire changing to easily achieve surface finishes of .2 Ra. (Click on photo to enlarge it)
As consumer products continue to shrink in size, die shops such as Scenic Tool and Stamping face the challenge of developing highly intricate tooling for stamping the tiny components that make up miniature merchandise. As a result, an increasing number of these shops are incorporating high-precision wire EDMs like the Cut 2000 from GF AgieCharmilles that provide automatic wire-changing capability. uses the to easily switch wires of different sizes and materials.
Metal Cutting: Products

Advanced DNC for Multiple CNC Machine Tools

FactoryWiz DNC can be used to transfer data to machines acting as FTP Clients, FTP Servers, or Microsoft SMB servers. Lite “web client” stations can be deployed on the vast majority of operating systems with a web browser.
FactoryWiz DNC from Refresh Your Memory provides full simultaneous communication and full machine event/monitoring on every machine tool, with powerful remote-request and email capabilities from the machine control panel, mobile devices and more.

Bridge the Gap: Plan to Manufacturing Execution

Factory Track helps to simplify inventory management, automate data collection, eliminate errors and inventory write-offs, collect labor time and attendance, provide payroll applications, automate production schedule execution, dispatch operations and automate work center operations.
Built for the Cloud, Factory Track from Infor provides manufacturers with a comprehensive, easy to customize way to increase their operational efficiency and improve visibility across the warehouse and the shop floor.

Fine Tune Machine Tool Servo Drives

The Main Tuning Screen displays a single page simple layout that allows quick and easy access to any data.
The Auto-Tuning program from Fagor Automation fine tunes machine tool servo drives one axis at a time, all axes automatically, or even multi-machine tuning.
Events Calendar
September 8 - 13, 2014
McCormick Place -- Chicago, IL
September 10 - 11, 2014
Miller and Hobart Technology and Training Center -- Houston, TX
September 15 - 17, 2014
San Diego Convention Center -- San Deigo, CA
September 16 - 18, 2014
Houston, TX
September 17 - 18, 2014
John S. Knight Center -- Akron, OH